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After getting inspiration from t_bone and Skip I decided to have a go for myself, any comments, (good or bad, as long as it's constructive) always appreciated

The basic shape is incorrect. The side on looks ok, but front on the shape is too top heavy, it looks almost like a light bulb, they are supposed to have more weight in the shoulders. If you can fix that, you might be onto a winner.

Looks great so far. I FG'd the out side of mine too. Just for that exra little .001mm of room for my big ol noggin. The only areas on the inside that got FG were the face portion below the eyes (for thickness) and the part the goes over the shoulders (for extra strength). I actually peeled off a fair amount of the original paper model toward the end.

No, you dont need to spend any money to print out the files. You can get a pepakura viewer here http://www.tamasoft.co.jp/pepakura-e...ad/viewer.html for free. If you are interested in the Royal guard template you can buy it from Skip aka Skupilkinson. He makes awesome templates! If you want to design your own templates then I believe it costs some money to buy that program.

No, you dont need to spend any money to print out the files. You can get a pepakura viewer here http://www.tamasoft.co.jp/pepakura-e...ad/viewer.html for free. If you are interested in the Royal guard template you can buy it from Skip aka Skupilkinson. He makes awesome templates! If you want to design your own templates then I believe it costs some money to buy that program.